Electrical connecting devices for terminating cords and methods of assembling the devices to cords

ABSTRACT

A one piece plug for terminating a cord to connect electrically the cord to components in a telephone apparatus is constructed with features advantageous to the assembly of the cord with the plug. The plug has a base molded with a cover hinged integrally to one end of the base and in an open position. This avoids the alignment of the cover with the base during assembly with the cord. Also, the base is formed with a cord-input aperture in the one end and which advantageously circumscribes substantially the cord periphery to maintain the cord within the plug during assembly operations. A leading portion of the cord is inserted into the aperture and extended past the other end of the plug. The jacket is removed from the leading portion to expose individually insulated conductors. Then the cord is retracted and the conductors fanned out into associated troughs having the same spacing as the components. The cover is closed and bonded to the base to confine the conductors and prevent unintended lateral and longitudinal movement. Flat terminals are inserted into the base to move internal contacting portions thereof into engagement with the conductors. External contacting portions of the terminals engage associated components of the telephone apparatus when the plug is inserted thereinto.

United States Patent Hardesty Sept. 10, 1974 ELECTRICAL CONNECTINGDEVICES FOR TERMINATING CORDS AND METHODS OF ASSEMBLING THE DEVICES TOCORDS Inventor: Edwin C. Hardesty, Perry Hall, Md.

Assignee: Western Electric Company,

Incorporated, New York, N.Y.

Filed: Dec. 4, 1972 Appl. No.: 311,575

U.S. Cl. 339/99 R, 339/105, 29/629 Int. Cl. HOlr 9/08, HOlr 13/58 Fieldof Search 339/97-99,

References Cited UNITED STATES PATENTS FOREIGN PATENTS OR APPLICATIONS544,048 l/l965 Belgium 339/99 R Primary ExaminerBobby R. Gay AssistantExaminerLawrence J. Staab Attorney, Agent, or Firm-E. W. Somers [57]ABSTRACT A one piece plug for terminating a cord to connect electricallythe cord to components in a telephone apparatus is constructed withfeatures advantageous to the assembly of the cord with the plug, Theplug has a base molded with a cover hinged integrally to one end of thebase and in an open position. This avoids the alignment of the coverwith the base during assembly with the cord. Also, the base is formedwith a cordinput aperture in the one end and which advantageouslycircumscribes substantially the cord periphery to maintain the cordwithin the plug during assembly operations. A leading portion of thecord is inserted into the aperture and extended past the other end ofthe plug. The jacket is removed from the leading portion to exposeindividually insulated conductors. Then the cord is retracted and theconductors fanned out into associated troughs having the same spacing asthe components. The cover is closed and bonded to the base to confinethe conductors and prevent unintended lateral and longitudinal movement.Flat terminals are inserted into the base to move internal contactingportions thereof into engagement with the conductors. Externalcontacting portions of the terminals engage associated components of thetelephone apparatus when the plug is inserted thereinto.

13 Claims, 10 Drawing Figures PATENTED SEPI 01974 SHEET 1 OF 4PAIENTEDSEPIOIQM 3.835.445

sum 2 0r 4 PAIENTEDSEP 1 0w sum u or 4 ELECTRICAL CONNECTING DEVICES FORTERMINATING CORDS AND METHODS OF ASSEMBLING THE DEVICES TO CORDSBACKGROUND OF THE INVENTION 1. Field of the Invention The inventionrelates to devices for making electrical connections and to methods ofmaking such connec- V tions, and more particularly, to devices formaking electrical connections between a cord comprising flexibleconductors and terminals wherein conductive terminals are combined withdielectric members to form plugs and methods of assembling the cord andthe devices.

2. Description of the- Prior Art In the telephone industry, increasinguse is being made of plug-type connectors on straight and retractilehandset and line cords which are used between a base and a handset of atelephone and between the base and a terminal. In the presently-usedplugs, a terminal is applied to each of a plurality of insulatedconductors contained within a jacketed length of retractile cordage.These terminals are mounted within a dielectric structure which isattached securely to the associated cordage. The dielectric portions ofthe plugs, which are mounted on both ends of a length of the cordage,cooperate with receptacles in the handset and the base of the telephoneto properly align the terminals of the plug with mating terminals withinthe components of the telephone.

One presently used plug is disclosed in US. Pat. No. 3,699,498 issued onOct. 17, 1972. Conductors are confined in conductorreceiving troughsformed in a dielectric base by a cover bonded to the base. Flatterminals are inserted into individual grooves in the base in aside-by-side arrangement with contact portions thereof extending intoengagement with the conductors. When the plug is inserted into a jack ina telephone handset, portions of terminals in the jack are received inassociated ones of the grooves to engage side portions of the plugterminals.

The provisions in the just-identified plug for contacting the externalcomponent may be changed to that described in a continuation-in-partapplication filed on Mar. 8, 1972 in the names of E. C. Hardesty, C. L.Krumreich, A. E. Mulbarger, Jr. and S. W. Walden. There, the externalcontact portions of the terminal consists of an edge exposed to theexterior of a dielectric enclosure.

Of course, the terminals in the plugs are aligned with the contactelements in the telephone handset. The cord conductors in thejust-described system are aligned with the terminals. In some systems,the conductors of the cord may not be spaced the same as the contactelements in the telephone. Provisions must be made for spreading out theconductors to be engaged by terminals which are aligned with theexternal contact elements.

A presently used plug incorporating provisions for spacing out theconductors is disclosed in U.S. Pat. No. 3,617,982 issued on Nov. 2,1971. In this plug, a plurality of conductors are led into a back end ofthe plug, then the conductors are passed over the front end of the plugand connected to end portions of terminals seated on the underside ofthe plug.

The recent trend to the use of plug in type conductors in telephonehandsets as exemplified by that shown in US. Pat. No. 3,617,982 has beenaccompanied by the use of fiat telephone cords. The use of flat cordslends toward increased. manufacturing economies provided that the plugis designed with regard for a flat cord system. Also, recent advances interminal design in plugs may be adapted for use with fiat cords on aproduction line basis.

The prior art related to connecting electrically a plug to conductorsheld together in a flat configuration is shown for example in US. Pat.No. 2,929,043. There a twin-lead antenna cable is led in through anopening formed between a body and a separate hinged cover plate. Thecover plate is provided with facilities for engaging and pressing thecable into electrical contact with converging toothed contact plates.

Also available is a solderless wire connector (US. Pat. No. 3,5 76,5 l8) containing a slotted resilient metal contact plate. The plate istransversely supported within a base contoured to support conductors tobe connected. The base has a hinged cover and a collar which cooperateswith a collar on the cover to provide strain relief for the conductorswhen the cover is closed.

SUMMARY OF THE INVENTION This invention provides a device for makingelectrical connections. The device can be fabricated by usingconventional molding techniques and can be assembled to a cord beforethe cord is heat treated to achieve retractile properties. Methods areprovided for assembling plugs to conductors and for establishingelectrical connections between the conductors and associated terminals.

An electrical connecting device which embodies the invention is moldedto include a base with a cover hinged integrally with the base and in anopen position. The base is formed with a plurality of conductorreceivingtroughs. A leading end of a cord is inserted through an opening in thebase which circumscribes substantially the periphery of the cord andwhich is adjacent the hinge and advanced to extend the leading endbeyond the plug. The jacket is removed from a leading portion of thecord and the cord is retracted to fan out and position each conductor ina trough. Then, the cover is closed and bonded to the base to confineeach conductor in a trough and to engage a portion of the jacket toprovide strain relief therefor. Individual strain relief is alsoprovided for each conductor. Flat blade-like terminals are inserted froman external face of the base into terminal-receiving grooves which arealigned with and which communicate with associated ones of the troughs.The terminals have tangs which extend into the troughs to makeelectrical contact with associated ones of the conductors.

BRIEF DESCRIPTION OF THE DRAWINGS Other features of the presentinvention will be more readily understood from the following detaileddescription of specified embodiments thereof when read in conjunctionwith accompanying drawings, in which:

FIG. 1 is a perspective view of a telephone set showing the inventiveplugs inserted into a handset and a base portion thereof;

FIG. 2 is a perspective view of one of the plugs with a cord andterminals prior to assembly with the plug for purposes of clarity andfurther showing a hinged dielectric portion of the plug in an openposition;

FIG. 3 is a perspective view of the plug shown in FIG. 2 with theconductors of the cord fanned out and received in associated ones of aplurality of conductorreceiving troughs;

FIGS. 4A4D are a sequence of views in elevation partially in section andshowing the assembly of the plug with the cord and terminals inaccordance with the principles of this invention;

FIG. 5 is a view showing the relationship between the plug illustratedin FIG. 2 being inserted into a handset portion of the telephoneillustrated in FIG. 1;

FIG. 6 is a view similar to that of FIG. 5 but at a later time with theplug being seated and locked within the handset portion of thetelephone; and

FIG. 7 is a perspective view of an apparatus which may be used to carryout the steps of the methods of this invention.

DETAILED DESCRIPTION OVERALL with a plug, designated generally by thenumeral 14, at

the handset and thereof and at the base end thereof. The plug 14 hasfacilities for establishing an electrical connection between the cord 13and internal contacting components 16-16 of the telephone (see FIG. 5).

Referring now to FIG. 2, a more detailed view of the structure of theretractile cord 13 can be seen. The retractile cord 13 includes a jacket17 and a plurality of insulated conductors 18-18. The free end portionof each of the conductors 18-18 is designed to be connected to anassociated one of a plurality of terminals 19-19.

Miniature plugs disclosed in the prior art may be advantageously used inmany telephone environments where the insulated conductors 18-18 havethe same spacing (0.037 inch) as the external components 16-16 withwhich the plug 14 makes contact. There are some telephone apparatushaving external components which are spaced further apart (0.125 inch)than conductors 18l8 in the cord '13 to be connected thereto. Thisrequires a fanning out of the conductors 18-18 in assembling the cord 13to the plug 14 which is not feasible with some of the heretoforediscussed prior art plugs. Plugs constructed in accordance with thepresent inventions permit the fannout out of the conductors 18l8 to bealigned with terminals which are aligned with external contactcomponents.

DIELECTRIC PORTION The detailed construction of the plug 14 is shown inFIGS. 2, 3, and 4. A rigid, dielectric base, designated generally by thenumber, 30, is designed to be easily molded by using conventionalinjection-molding techniques. The rigid. dielectric base has a free end31, a cord-input end 32 and a terminal-side 33 (see FIG. 4A).

7 It may be observed from FIGS. 3 and 4D that the base 30 is formed witha cord-input aperture 34 which circumscribes substantially the portionof the jacket 17 of the cord 13 extending therethrough. As can best beseen in FIG. 4A, the cord-input aperture 34 is formed entirely in thebase 30 of the plug 14 and has a flared entrance to facilitate insertionof a leading end of the cord 13. The cord-input aperture 34 opens into acavity 36 which terminates in a ledge 37 at the free end 31 of the base30. This facilitates the automatic assembly of the plug 14 to the cord13.

As has been noted, the formation of the cord-input aperture 34 entirelyin the base 30 and sized to substantially circumscribe the cord 13 isadvantageous during the assembly of the cord to the plug 14. This holdsthe cord 13 while other operations are performed by automated equipment.This is unlike prior art connectors having separate base and cover. Inthose, a portion of a conductor-access opening is formed in the base anda portion in a lid which is later bonded thereto. The cord 13 isgenerally positioned in the portion of the opening in the base and thenthe cover is applied. This will not suffice to hold the cord 13 in thebase during assembly without additional steps and equipment.

A plurality of longitudinally extending partitions 38-38 are molded withthe dielectric base 30 and extend into the cavity 36. A plurality ofconductorreceiving troughs 39-39 (FIG. 2) are formed between thepartitions 38-38 and open to the free end 31. The conductor-receivingtroughs 3939 are designed to receive associated ones of the conductors18l8. Each of the troughs 39-39 is dimensioned so that the conductor 18therein cannot move laterally therein. This is necessary to insure thatduring the insertion of the terminals 19-19, the terminals remainaligned with the conductors 18-18 to make electrical engagementtherewith.

It may be observed from FIG. 2 that the bottoms of the troughs 3939 aresubstantially coplanar with the top surface of the ledge 37. Thisfacilitates the use of the ledge 37 for conductor cut-off during theassembly of the plug 14 to the cord 13.

The partitions 38-38 are discontinued somewhat short of the conductoraccess opening 34 and emerge into a sloping surface 41 formed adjacentthe access opening. Attention is also directed to energy directors 42-42formed longitudinally along the partitions 38-38. The energy directors42-42 are dimensioned to provide for adequate bonding of a cover 46 tothe base 30 of the plug 14 in accordance with the specificationsprovided by manufacturers of commercial ultrasonic equipment. Forexample, see D. J. Kolb Designing Plastic Parts for Ultrasonic Assemblyin the Mar. 16, 1967 issue of Machine Design.

The cover 46 is molded integrally with the dielectric base 30 and ismounted pivotally along a plastic hinge 47 (see FIGS. 2, 3, and 4). Theplastic hinge 47 extends transversely along the dielectric base 30.

The use of the hinged cover 46 offers certain advantages. Since it ispre-attached to the base 30, alignment problems on closure arecircumvented. Also, by molding the cover integrally with the base 30 ina open position, the step of hingeing a separate part to the base issaved. Moreover, molding the cover in an open position presents the plugin a ready-for-assembly condition with no additional preparationnecessary.

As can also be seen in FIG. 2, the cover 46 has a plurality of spacedparallel ribs 48-48 projecting therefrom toward the base 30. The ribs48-48 are positioned to be intermediate the partitions 38-38. Also, theribs 48-48 extend from the cover 46 a sufficient distance so that whenthe cover is closed and bonded to the base 30, the ribs will engage andconfine the associated ones of the conductors 18-18. In this way, whenthe cover 46 is closed, the ribs 48-48 engage the conductors 18-18received in the troughs 39-39 to secure the conductors within thetroughs.

The ability to be able to precisely confine the conductors 18-18 isespecially important. Prohibition against movement is necessary in orderto cause the terminals 19-19 to penetrate the nylon-insulated conductors18-18. The terminals 19-19 must be inserted with sufficiently highforces imparted thereto to penetrate the insulation. If the conductors18-18 were free to move laterally, the terminals 19-19 may very wellslice into the insulation on either side of the conductive elements andfail to establish engagement therewith.

The plug 14 also has provisions to alleviate strain relief on the cordjacket 17 during customer use. The cover 46 has a cord anchoring lug 49(see FIG. 4A) projecting from the underside thereof. As can be seen inFIG. 4D, the cord anchoring lug 49 is spaced along the underside of thecover 46 so that when the cover is closed, the anchoring lug is alignedwith a well 51 formed in the base 30. The well 51 communicates theexterior of the plug 14 with the cavity 36. When the cover 46 is closed(see FIG. 4D) with the cord 13 being inserted into the plug 14, theanchoring lug 49 engages the jacket 17 and urges a portion of the cord13 into the well 51. The cord 13 assumes a tortuous configuration aroundthe anchoring lug 49.

Strain relief is also provided for the individual conductors 18-18. Asis shown in FIG. 2, a plurality of conductor anchoring teeth 5252 areformed on the underside of the cover 46 intermediate the hinge 47 andthe free end thereof. The teeth 5252 are aligned with theconductor-receiving troughs 39-39. When the cover 46 is closed on thebase with the conductors 18-18 received within the troughs 39-39, theteeth 5252 engage associated ones of the conductors (see FIG. 4D) anddeform the insulation thereof to secure the conductors within the plug14.

In this way, the terminals 19-19 function only to make electricalcontact with the conductors 18-18 and are not required to retain theconductors and resist the forces imparted to the conductors duringcustomer use. These forces occur notwithstanding the anchoring of thecord 13. This is due to the jacket having a much greater elongation thanthe core of the cord 13. If strain relief were not provided for theconductors 18-18, desirably on an individual basis, pull-out of one ormore of the conductors may occur during use of the telephone.

As can best be seen in FIG. 4A, the plug 14 is formed with a pluralityof spaced parallel terminal-receiving openings in the form of grooves56-56 which are aligned on a one-to-one basis with associated ones ofthe conductor-receiving troughs 39-39. Each of the terminal-receivinggrooves 56-56 is of a length substantially equal the overall length of aterminal 19. Each of the terminal-receiving grooves 56-56 communicateswith the associated conductor-receiving trough 39 through a slot 57. Theslot 57 is shorter than the associated terminal-receiving groove 56 andis of a length slightly less than the out-to-out distance of thatportion of a terminal 19 which is to be received therein. The shorteningof the slots 57-57 from the terminalreceiving grooves 56-56 formsabutments 58-58 (see FIG. 4A for example).

Formed integrally with the dielectric portion 30 is a resilient lockingtab 61. The locking tab 61 is approximately 0.035 inch thick, 0.300 inchwide, 0.500 inch long, and is molded so that its longitudinal axis isoriented at an angle of approximately 15 with respect to the plane ofthe terminal-inserting side 33. A hinge end 62 of the locking tab 61 ismolded into one side of a bridge projection 63, substantially in themiddle of the projection.

The combined height of the bridge projection 63, thickness of thelocking tab 61 and resilience of the locking tab permits insertion ofthe plug 14 into the handset 12 between opposing surfaces 64 and 66 (seeFIG. 5). The tab 61 can be deflected inwardly of the dielectric base 30to become substantially coplanar with the outermost surface of thebridge projection (see FIG. 5) and be moved slidably in engagement withthe surface 64.

After being released, the locking tab 61 will resume its originallymolded shape and orientation because of its natural resilience. Properresilience to provide the desired flexing properties can be incorporatedinto the locking tab 61 when it is molded from polycarbonate with theaforementioned dimensions. The return of the tab 61 to its originallymolded shape causes the free end of the tab to be urged downwardly intoseating engagement with a ledge 67 (see FIG. 6) formed in the handset 12and the base 11. This locks the plug 14 to the handset 12 and insuresintegrity of the connection during customer use.

TERMINALS As can best be seen in FIG. 2, each one of the terminals 19-19is made from a generally flat strip of electrically conductive resilientmaterial such as Phosphor bronze. Moreover, each one of the terminals19-19 includes at least one contact or insulation-piercing tang 71 whichprovides electrical connection between the conductive portion of theconductor 18 and the associated one of the terminals 19-19.

Each of the blade-like terminals 19-19 also has a flat contact portion72 which is utilized to complete the connection between the associatedconductor 18 and an associated internal-contacting component 16illustrated in FIG. 5, and positioned in the telephone 10.

Provisions are also made for seating properly the terminals 19-19 withinthe associated terminal-receiving grooves 56-56. Each of the terminals19-19 is formed with positioning shoulders 74-74. These shoulders 74-74engage with the end faces of the grooves 56-56 to locate the terminals19-19 properly longitudinally within the grooves. The shoulders 74-74also engage with the abutments 58-58 to seat the terminals 19-19 withinthe grooves properly with respect to depth. This insures that theterminals 19-19 are seated at a distance spaced from the conductor suchthat the tangs 71-71 engage with the conductive portion of theconductor. If spaced excessively, the tangs 71-71 may not extend to theconductive portions; and if spaced too closely, there may be a deformingof the tangs or of the conductor.

There are also provisions for retaining the terminals 19-19 within theterminal-receiving grooves 56-56. Each of the terminals 19-19 is formedwith barbs 76-76 which extend from end ones of the tangs 71-71. Thesepenetrate the material of the plug which define the terminal-receivinggrooves 56-56 when the terminals are assembled therewith. The barbs76-76 dig into the end walls of each of the slots 57-57 to securelyanchor the terminal within the plug 14.

METHOD OF ASSEMBLING PLUG WITH CORD The construction of the plug 14 isespecially adapted to be used with flat cordage. Moreover, the plug 14is easily adapted to automated high speed manufacturing. In describingthe assembly of the plug 14 and the cord 13, reference will be made toFIGS. 4A-4D which depict the steps of the method. Reference will also bemade to FIG. 7 which illustrates an apparatus, designated generally bythe numeral 80, which is exemplary of apparatus which may be used tocarry out the steps of the method.

One of the plugs 14-14 with the cover 46 thereof in the open position ispositioned in a workholder 81 (see FIG. 7). Then a leading end of thejacketed cord 13 is inserted between a grooved roller 82 and a driveroller 83. The groove in the roller 82 is constructed so that when thecord 13 is positioned therein, portions of the cord extend above theperiphery of the roller. The drive roller 83 is mounted adjacent thegrooved roller 82 so as to engage the portions of the cord 13 exposedabove the groove. The drive roller 83 is turned to advance the leadingend of the cord 13 through the plug 14 until it extends well beyond thefree end 31 of the plug (see FIG. 4B).

A plate 84 and a spring-biased rod 86 are positioned between the base 30and the cover 46 prior to the advancement of the leading end of the cord13 through the plug 14. The cord 31 is advanced between the plate 84 andthe tops of the partitions 38-38. Since the outside diameter of the cord13 is significantly greater than the width of each of the troughs 39-39,successive sections of the cord are maintained in engagement with thetop surfaces of the partitions 38-38. The plate 84 is of assistance inmaintaining the path of the leading end of the cord 13 in apredetermined direction to facilitate further processing.

It is advantageous to construct the base 30 with the cord-input aperture34 which circumscribes substantially the cord 13. This provides totallateral support for the cord 13 intermediate the convolutions and thefree end thereof during its assembly with the plug 14. This is unlikeprior art devices wherein only the base may include a U-shaped opening.in assembling those devices, the cord 13 must be held within the openingduring the arrangement of the conductors 18-18 within the base and theassembly of a lid thereto.

in the next step of the inventive method, a stripping device 87 iscontrolled to remove a length of the jacket 17 from the cord 13. Thisexposes individual ones of the conductors 18-18 which have their ownprimary insulative covering. The stripping device 87 is then returned toan initial position.

Then the rotation of the drive roller 82 is reversed to withdraw theleading end portion of the cord toward and at least partially within theplug (see FIG. 4C). The cord 13 is retracted until the exposedindividual conductors 18-18 extend to a point which will be intermediatethe anchoring lug 49 and the anchoring teeth 52-52 (see FIG. 4D) whenthe cover is closed.

A combing head 91 is moved along a path spaced above and aligned withthat of the cord. Simultaneously with the retraction of the cord 13, theconductors 18-18 are fanned out and received separately in associatedones of the conductor-receiving troughs. The fanning out of theconductors 18-18 simultaneous with the retraction of the cord 13 isaccomplished by controlling a plurality of selectively movable cammingblades 88 and 89 (see FIG. 7) which are mounted in the head 91.

To describe the fanning out operation, it is assumed that the cord 13includes five conductors 18-18, a center conductor, two intermediateconductors and two outside conductors. As the cord 13 is retracted, the

.blades 88-88 are moved downwardly between the center and immediateconductors. Then the blades 88-88 are turned rotatably within the head91 to space apart the center and intermediate conductors. Simultaneouslytherewith, the blades 89-89 are moved downwardly between theintermediate and outer conductor 18-18 and turned. This causes theconductors 18-18 to be spaced apart and permit the plate 84 to cause theconductors to be moved into the troughs 39-39.

This is accomplished by controlling the rod 86 to urge the plate 84 intoengagement with the top surfaces of the partitions 38-38. This causesthe jacketed portions of the cord 13 extending from the cord inputaperture 37 to be urged into engagement with the sloping surface 41.Also, the individual conductors 18-18 are moved into associated ones ofthe troughs 39-39 and maintained therein by the plate 84.

Because the cord 13 is flat and because of the assembly process, theconductors 18-18 are spaced in a prearranged order in the troughs 39-39.It is unnecessary for an operator to identify the conductors 18-18 priorto the electrical connection with ones of the terminals 19-19. The orderin the cord 13 is maintained in the plug 30 to correspond to the orderof engagement with the external contacting components 16-16.

In a next step of the method which embodies the principles of thisinvention, an ultrasonic bonding tool 92 is moved downwardly intoengagement with the dielectric cover 46. The bonding tool 92 is movedfurther downwardly to apply forces to the cover 46 to move pivotally thecover about the hinge 47 and to engage the cover with the base 30 (seeFIG. 4D). Simultaneously, therod 86 is moved toward the free end 31 ofthe base while maintaining pressure against the plate 84. This maintainsthe plate 84 in engagement with the top surfaces of the partitions 38-38to maintain the conductors 18-18 within the troughs 39-39 while thecover 46 is being closed.

As this is done, the anchoring lug 49 engages the jacketed portion ofthe cord 13 while the anchoring teeth 52-52 engage the individualconductors 18-18. This arrangement provides strain relief for both thecord 13 and for the individual conductors 18-18. With these provisionsfor strain relief, the maintenance of electrical continuity is greatlyenhanced. Notwithstanding the very great difference in elongationcharacteristics between the jacket material and the individualconductors, the individual clamping of each conductor 18 will maintainthe conductors in the troughs when subjected to forces imparted theretoduring customer use.

As the cover 46 is moved pivotally to a closed position, the plate 84 iswithdrawn slidably toward the free end 31 of the plug 14. Duringwithdrawal, the plate 84 is maintained in engagement with portions ofthe top surfaces of the partitions 38-38. After the plate 84 and rod 86are withdrawn completely and the cover 46 closed, the ultrasonic bondingtool 92 is controlled to bond the cover to the base 30.

The advantages of the cover 46 being integrally hinged with the base 30should be apparent. Additional assembly steps and apparatus therefor areunnecessary. Also, tedious alignment problems of miniature bases andseparate covers prior to bonding are overcome.

Moreover, the construction of the plug with the cordinput aperture 34totally within the base 30 and with the cover 46 hinged to the base 30,facilitates the fanning out of the conductors 18-18. Since the cord 13is held laterally at the cord-input aperture 34, additional holdingfacilities areunnecessary and only the facilities for fanning out theconductors 18-18 are required.

It should also be noted that as the cover 46 is closed on the base 30and bonded ultrasonically thereto, the ribs 48 are received betweenassociated conductors 18-18 to complete the lateral confinement thereofin the associated throughs 39-39.

The free end portions of the conductors 18-18 are trimmed off with acutting device 93 and using the ledge 37 as a bearing surface. Theextension onto the ledge 37 and the cut off is necessary to compensatefor the snubbing action of the closing of the cover 46 on theconductors. Had the conductors 18-18 been retracted to precisely alignthe ends thereof with the ends of the troughs, then when the cover isclosed, the snubbing action would cause the conductors to movelongitudinally within the troughs. Also, the paths of the conductorsl8l8 within the plug 14 vary. Presizing the conductors 18-18 wouldresult in outside ones of the conductors being withdrawn in the troughs39-39. This could possibly result in the loss of electrical contact ofthe outer ones of the terminals 19-19 with the outer conductors, i.e.,those conductors adjacent the sides of the base 30.

The above-described arrangement is easily adaptable to an automationprocess. The flat cord 13 has the conductors 18-18 in an orderedpredetermined sequence which are to be received in the same order in thetroughs 39-39. The retraction of the length of the cord 13 back into thedielectric portion 30 maintains the conductors in the same order and nofurther identification is required.

in order to complete the assembly of the plug 14 to an end of the cord13, five of the terminals 19-19 are inserted into the plug. Theblade-like terminals 19-19 are inserted from the terminal-receiving face33 of the plug 14 into associated ones of the terminal-receiving grooves56-56 until the positioning shoulders 74-74 seat into engagement withthe abutments 58-58 (see FIG. 4D). At that time, the contact tangs 71-71extend through the aligned slots 57-57 and into the associated troughs39-39. The tangs 71-71 penetrate the insulation of the conductors 18-18confined in the troughs 39-39 and establish electrical contact with theconducitve elements thereof.

Also, the barbs 76-76 are caused to become embedded in the portion ofthe dielectric base 30 which defines the slots 57-57. This anchors theterminals- 71-71 against movement or inadvertent removal from the base30.

In use, the lower edge portion of each of the bladelike terminals 19-19engages electrically with an associated external contacting portion 16(see FIG. 5).

Of course, apparatus other than the apparatus 80 may be used to practicethe methods of this invention. For example, the assembly of the plug 14to the cord 13 could be accomplished by using'a turntabletnot shown)with facilities for inserting the cord, stripping the cord etc. arrangedabout the periphery of the turntable. Successive cords 13-13 andassociated plugs 14-14 are moved with the turntable (not shown) throughthe work stations.

It is to be understood that the above-described arrangements are simplyillustrative of the invention. Other arrangements may be devised bythose skilled in the art which will embody the principles of theinvention and fall within the spirit and scope thereof.

What is claimed is: 1. An electrical connector for terminating a cordincluding a plurality of insulated conductors and for making electricalcontact external to the connector, which comprises:

a base, which includes a cord-input end having an aperture for receivingand substantially circumscribing the cord, the base also including aportion having conductor-receiving troughs and a plurality ofterminal-receiving openings extending generally parallel to andcommunicating with the troughs and the exterior of the connector, theinverts of the troughs to which the terminal-receiving openingscommunicate being in substantially the same plane as a portion of thewall of the cord-input opening, the base being formed with a wellbetween the cord-input end and the conductor-receiving troughs forreceiving the portion of the jacketed cord, the base being formed with aramp extending from the well to the troughs to facilitate the advance ofa leading end of a cord from the cord input end beyond the troughs; aplurality of electrically conductive blade-like terminals positionedwithin the base each of which includes: an internal contact portionextending into the trough for piercing the insulation of and makingelectrical engagement with the conductor in the trough; and

an external contact portion positioned within the associatedterminal-receiving opening for making electrical contact external to theconnector; and

a cover having one end formed integrally with the base along a webportion which is substantially less in thickness than the cover or thewalls of the base defining the cord-input aperture, the web portionbeing adjacent the cord-input end and moveable with respect thereto tocause a portion thereof to engage the portion of the base having theconductor-receiving troughs to confine the conductors and to preventlateral movement thereof to insure that the positioning of the terminalswithin the openings cause the internal contact portions of the terminalsto engage electrically the associated insulated conductors, the coveralso being formed with an anchoring lug extending from the undersidethereof and which engages the jacketed portion of the cord after thecord has been inserted into the cord-receiving opening and the coverclosed, the portion of the cord engaged by the anchoring lug beingformed along a tortuous path around the anchoring lug and extending intothe well to provide strain relief for the cord during use thereof.

2. The electrical connector of claim 1, wherein the cover is formed witha plurality of conductor-engaging teeth on the underside thereof andextending toward the base, each of the teeth being aligned with anassociated conductor-receiving trough. so that when the cover is closedon the base, each of the teeth engages the insulation of the conductorpositioned in the associated conductor-receiving trough to providestrain relief for the individual conductors during use.

3. The electrical connector of claim 1, wherein the free end of the baseextends beyond the cover when the cover is in a closed position toprovide a bearing surface for cutting off exposed end portions of theconductors which extend beyond the free end of the cover.

4. The connector of claim 1, wherein the terminalreceiving openingsinclude a plurality of spaced grooves opening to an external surface ofthe connector and associated slots communicating the grooves withassociated ones of the troughs, each of the slots being of a size topermit the internal contact portion of a terminal to pass therethrough.

5. The connector of claim 4, wherein the internal contact portions ofeach terminal includes a plurality of contact tangs which extend throughthe slots and into electrical engagement with the conductor in theassociated trough.

6. The connector of claim 5, wherein each of the terminals is formedwith barbs extending from portions of the tangs which are positionedwithin the slots and an overall longitudinal dimension thereof isslightly greater than the longitudinal dimension of the slot whichcommunicates the associated groove and trough to facilitate the endbarbs of the terminal becoming embeded in the walls of the slot when theterminals are inserted to anchor the terminals within the base.

7. The connector of claim 4, wherein each of the grooves of eachterminal-receiving opening is formed to extend beyond the ends of eachassociated slot to form an abutment at each end of the groove.

8. The connector of claim 7, wherein each of the terminals includes ashoulder at each end thereof for engaging the abutments of theassociated terminalreceiving groove to seat the terminal properly withinthe opening.

9. The connector of claim 1, wherein the cord-input aperture has aninner portion approximately the same cross-section of the cord with thewalls of the aperture diverging continuously from the inner portion tothe cord-input end of the connector and forming a flared inlet tofacilitate insertion of the leading end of the cord.

10. A method of assembling a device to a cord for connectingelectrically individual conductors which comprise the cord to associatedcomponents external to the device, the device including a base having acord-input aperture which circumscribes and is in engagementsubstantially with the periphery of a section of the cord extendingtherethrough, the base further having conductor-receiving troughs andterminalreceiving openings communicating with associated troughs and acover hinged integrally to the base adjacent the cord-input aperture andadapted to mate with the base, which includes the steps of:

holding the base with the cover hinged open therefrom;

inserting the leading portion of the cord into the cord-input aperture;

causing relative motion between the device and the cord to advance theleading portion of the cord beyond the base;

exposing the individual insulated conductors of a predetermined lengthof the leading portion of the cord by removing the jacket therefrom;

retracting at least a section of the leading portion of the cord withinthe base; while positioning the individual ones of the conductors withinassociated ones of the troughs;

causing the cover to be closed on and secured to the base to confine theconductors within the associated troughs and prevent unintended lateraland longitudinal movement thereof; and

inserting and seating terminals in the terminalreceiving openings suchthat internal contact portions thereof extend into the troughs andpierce the insulation of the associated conductors to establish anelectrical connection with the conductors and to expose external contactportions thereof for engagement with the external components.

11. The method of claim 10, wherein the cord is inserted into the devicewith the conductors arranged in a specific orientation such that whenjacket is removed from leading portion of the cord, the. orientation ofthe conductors corresponds to that of the associated conductor-receivingtroughs thereby obviating identification of the individual conductorsbefore placement thereof in the associated troughs.

12. The method of claim 10, wherein the spacing of the troughscorresponding to the spacing of the external components is greater thanthat of the conductors within the jacketed cord and positioning of theconductors in the troughs includes fanning out the conductors while thecord is being retracted to align the conductors with the associatedtroughs.

13. The method of claim 10, wherein the cord is retracted so thatleading portions of the individual conductors extend beyond a free endof the device opposite that end having the cord-input aperture and themethod includes the further step of severing those portions of theconductors extending beyond the device subsequent to the closing of thecover.

1. An electrical connector for terminating a cord including a pluralityof insulated conductors and for making electrical contact external tothe connector, which comprises: a base, which includes a cord-input endhaving an aperture for receiving and substantially circumscribing thecord, the base also including a portion having conductor-receivingtroughs and a plurality of terminal-receiving openings extendinggenerally parallel to and communicating with the troughs and theexterior of the connector, the inverts of the troughs to which theterminal-receiving openings communicate being in substantially the sameplane as a portion of the wall of the cord-input opening, the base beingformed with a well between the cordinput end and the conductor-receivingtroughs for receiving the portion of the jacketed cord, the base beingformed with a ramp extending from the well to the troughs to facilitatethe advance of a leading end of a cord from the cord input end beyondthe troughs; a plurality of electrically conductive blade-like terminalspositioned within the base each of which includes: an internal contactportion extending into the trough for piercing the insulation of andmaking electrical engagement with the conductor in the trough; and anexternal contact portion positioned within the associatedterminal-receiving opening for making electrical contact external to theconnector; and a cover having one end formed integrally with the basealong a web portion which is substantially less in thickness than thecover or the walls of the base defining the cord-input aperture, the webportion being adjacent the cord-input end and moveable with respectthereto to cause a portion thereof to engage the portion of the basehaving the conductor-receiving troughs to confine the conductors and toprevent lateral movement thereof to insure that the positioning of theterminals within the openings cause the internal contact portions of theterminals to engage electrically the associated insulated conductors,the cover also being formed with an anchoring lug extending from theunderside thereof and which engages the jacketed portion of the cordafter the cord has been inserted into the cord-receiving opening and thecover closed, the portion of the cord engaged by the anchoring lug beingformed along a tortuous path around the anchoring lug and extending intothe well to provide strain relief foR the cord during use thereof. 2.The electrical connector of claim 1, wherein the cover is formed with aplurality of conductor-engaging teeth on the underside thereof andextending toward the base, each of the teeth being aligned with anassociated conductor-receiving trough, so that when the cover is closedon the base, each of the teeth engages the insulation of the conductorpositioned in the associated conductor-receiving trough to providestrain relief for the individual conductors during use.
 3. Theelectrical connector of claim 1, wherein the free end of the baseextends beyond the cover when the cover is in a closed position toprovide a bearing surface for cutting off exposed end portions of theconductors which extend beyond the free end of the cover.
 4. Theconnector of claim 1, wherein the terminal-receiving openings include aplurality of spaced grooves opening to an external surface of theconnector and associated slots communicating the grooves with associatedones of the troughs, each of the slots being of a size to permit theinternal contact portion of a terminal to pass therethrough.
 5. Theconnector of claim 4, wherein the internal contact portions of eachterminal includes a plurality of contact tangs which extend through theslots and into electrical engagement with the conductor in theassociated trough.
 6. The connector of claim 5, wherein each of theterminals is formed with barbs extending from portions of the tangswhich are positioned within the slots and an overall longitudinaldimension thereof is slightly greater than the longitudinal dimension ofthe slot which communicates the associated groove and trough tofacilitate the end barbs of the terminal becoming embeded in the wallsof the slot when the terminals are inserted to anchor the terminalswithin the base.
 7. The connector of claim 4, wherein each of thegrooves of each terminal-receiving opening is formed to extend beyondthe ends of each associated slot to form an abutment at each end of thegroove.
 8. The connector of claim 7, wherein each of the terminalsincludes a shoulder at each end thereof for engaging the abutments ofthe associated terminal-receiving groove to seat the terminal properlywithin the opening.
 9. The connector of claim 1, wherein the cord-inputaperture has an inner portion approximately the same cross-section ofthe cord with the walls of the aperture diverging continuously from theinner portion to the cord-input end of the connector and forming aflared inlet to facilitate insertion of the leading end of the cord. 10.A method of assembling a device to a cord for connecting electricallyindividual conductors which comprise the cord to associated componentsexternal to the device, the device including a base having a cord-inputaperture which circumscribes and is in engagement substantially with theperiphery of a section of the cord extending therethrough, the basefurther having conductor-receiving troughs and terminal-receivingopenings communicating with associated troughs and a cover hingedintegrally to the base adjacent the cord-input aperture and adapted tomate with the base, which includes the steps of: holding the base withthe cover hinged open therefrom; inserting the leading portion of thecord into the cord-input aperture; causing relative motion between thedevice and the cord to advance the leading portion of the cord beyondthe base; exposing the individual insulated conductors of apredetermined length of the leading portion of the cord by removing thejacket therefrom; retracting at least a section of the leading portionof the cord within the base; while positioning the individual ones ofthe conductors within associated ones of the troughs; causing the coverto be closed on and secured to the base to confine the conductors withinthe associated troughs and prevent unintended lateral and longitudinalmovement thereof; and inserting and seating terminals in theterminAl-receiving openings such that internal contact portions thereofextend into the troughs and pierce the insulation of the associatedconductors to establish an electrical connection with the conductors andto expose external contact portions thereof for engagement with theexternal components.
 11. The method of claim 10, wherein the cord isinserted into the device with the conductors arranged in a specificorientation such that when jacket is removed from leading portion of thecord, the orientation of the conductors corresponds to that of theassociated conductor-receiving troughs thereby obviating identificationof the individual conductors before placement thereof in the associatedtroughs.
 12. The method of claim 10, wherein the spacing of the troughscorresponding to the spacing of the external components is greater thanthat of the conductors within the jacketed cord and positioning of theconductors in the troughs includes fanning out the conductors while thecord is being retracted to align the conductors with the associatedtroughs.
 13. The method of claim 10, wherein the cord is retracted sothat leading portions of the individual conductors extend beyond a freeend of the device opposite that end having the cord-input aperture andthe method includes the further step of severing those portions of theconductors extending beyond the device subsequent to the closing of thecover.